Method of cutting gears



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*i R's.l DRUMMOND METHOD OF CUTTING GEARS Filed Aug. 10, 193e 9y Sheets-Sheet l INVEN TOR.

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Jam 20, 1942 R. s. DRUMMOND METHOD OF CUTTING GEARS Filed Aug. lO, 1936 9 Sheets-Sheet 2 I.\'VE.\ TOR.

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METHOD OF CUTTING GEARS 9 Sheets-Sheet 3 Filed Aug. l0, 1936 INVENTOR.

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METHOD OF CUTTING GEARS Filed Aug. l0, 1936 9 Sheets-Sheet 5 INVENTOR.

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METHOD OF CUTTING GEARS Filed Aug. lO, 1936 9 Sheets-Sheet 7 WWW/m INVENTOR B Y Roel-:RT smaunmono, what. www

Jas. 20, 1942. R. s. DRUMMOND 2,270,422

METHODOF CUTTING GEARS Filed Aug. l0, 1936 9 Sheets-Sheet 8 NVENTOR Ei-E E ROBERT s.oRuMMoVNo um AMJ-03km.,

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A TTORNE y s @eef cn noem ,5 Patented `Ian. 20, 1942 UNITED STATES PATENT OFFICE" 6 Claims.

The invention relates to the nishing of gears which have been roughly fashioned by any suitable method such, for instance, as by hobbing.

This application is a continuation in part of my co-pending application, Serial No. 626,768, iiled July 30, 1932.

It is one of the objects of the invention to rapidly remove sufiicient stock to correct all errors in the original form and to obtain a high degree of accuracy as to tooth contour, helical angle, circular pitch, indexing, etc. My new method is particularly adapted for correcting the form of a rough cut gear prior to the heat treatment of the same so that it is unnecessary to eiiect any further finishing action after heat treatment, or if some nishing treatment is still desired, the amount of grinding or lapping necessary is reduced to the minimum.

Broadly stated, my improvement consists in running the rough gear in mesh with a. rotary finishing tool having gear teeth, the helix angle of which are so selected with respect to the helix angle of the teeth of the gear to be nished that when said members are in proper mesh the axes of said members are crossed at an angle between 3 and 30. The rotary gear tool is provided with one or more grooves extending in a direction from the top to the bottom of each tooth forming cutting edges. The gear teeth of the cutting tool are maintained in pressure contact with the teeth of the gear to be nished by maintaining an axial pressure between the axes. thus causing the cutting edges on the tool to cut or shave the sides of the work teeth. A feed movement is also provided causing the cutting tool and gear to be moved relative to one another in the direction of the axis of the gear thereby causing the cutting action to be spread over the entire face width of the gear to be nished.

The rotary gear cutting tool may be of various different constructions and the tool itself forms the subject matter of other patent applications. This application relates to the method of cutting or shaving gears with a rotary gear cutting tool and involves new principles which so far as I am aware were unrecognized prior to my invention.

Machines on which my method may be carried out may be constructed in various ways and form the subject matter of other patent applications. However, in order to fully point out all of the various new features of my method of cutting or shaving gears, it is thought desirable in this appliation to illustrate and describe certain machines and certain cutting tools which are not in themselves claimed in this application. Therefore I shall first describe the machines and the cutting tools, and then point out more in detail the novel methods underlying the invention claimed in this application.

In the drawings:

Figure 1 is a perspective view of a machine embodying my invention, showing one form of rotary gear cutting tool in engagement with a gear to be cut or shaved:

Figure 2 is a. vertical central section through the machine:

Figure 3 is a sectional plan view;

Figure 4 is a diagram illustrating the operation of the machine and the electric timing mechanism therefor;

Figure 5 is a perspective view oi' a moded construction of a rotary gear cutting machine;

Figure 6 is a sectional side elevation thereof;

Figure '7 is a vertical section on the line 1-1 of Figure 6;

Figure 8 is a vertical section on the line 8-8 of Figure 6;

Figure 9 is a. sectional plan view on the line 9-9 of Figure 8;

Figure 10 is a vertical section on the line |0-I0 of Figure 8;

Figure 11 is an electrical diagram;

Figure 12 is a perspective view of one form of rotary gear cutting tool:

Figure 13 isa top plan view of a modiiied form of rotary gear cutting tool;

Figure 13a is a side view of a tooth of the cutter of Figure 13;

Figure 14 is a perspective view of another rotary gear cutting tool;

Figure 15 is a perspective view showing a rotary gear cutting tool in operative relation to a helical gear to be shaved;

Figure 16 is a diagrammatic view representing the developed pitch plane of a gear and rotary :gagging lfool illustrating the cutting action of the Figure 17 is a diagram similar to Figure 16 showing the cutting action of the tools illustrated in Figures 14 and 15;

Figure 18 is a diagram o! a gear tooth in perspective showing action of the rotary gear cutting tool without axial feed movement;

Figures 19, 20, 21 and 22 are diagrams illustrating the preferred relation between the axial feed movement and the rotation of the cutter:

Figure 23 is a diagrammatic representation of one tooth of a helical cutter illustrating the normal cutting action;

Figure 24 is a similar diagram illustrating the cutting action of the cutter when used for shoulder cutting;

Figure 25 is a diagrammatic plan view of a cutter and a work gear arranged for shoulder cutting;

Figure 26 is a diagrammatic plan view of a cutter and a work gear arranged for normal cutting;

Figure 27 is a fragmentary edge view of a. rotary cutter of the type shown in Figure 14;

Figure 28 is a diagram illustrating the band of contact on a spur gear when mating with a helical gear in a crossed axes relationship;

Figure 29 is a. diagram illustrating the band of contact on a helical gear when mating with another gear in a crossed axes relationship;

Figure 30 is a diagram illustrating the path of the cutting edges when cutting a helical gear;

Figure 31 is a diagram similar to Figure 30 showing the path of cutter contacts when the axial feed is excessive.

Machine for carrying out the method of cutting gears One form of a machine in which my method of cutting gears may be carried out is shown in Figures 1 to 4 and comprises essentially an arbor A for the gear to be finished, an arbor B for the nishing tool adjustable in spacing and in angular relation to each other so that the work may be placed in intermeshing relation with the tool. The arbor vB is driven from a motor C through the medium of a step-down transmission D, shaft The arbor A D', pulley D2, belt E and pulley E'. is mounted between head and tail stocks F and G on a carriage H which is slidably mounted on ways I on a head I vertically adjustable on a column J. This column is supported on arcuate ways K on the bed L on which latter is mounted the arbor B and drive mechanism therefor. Thur, the arbor A may be angularly adjusted with respect to the arbor B by adjustment of the column J around the arcuate ways K. The spacing between the arbors can be adjusted by raising or lowering the head I on the column J and the arbor A may be axially reciprocated by movement of the carriage H on the ways I. As shown, the mechanism for accomplishing this reciprocation consists of a further step-down gearing M which actuates a crank M adjustable in throw which in turn is connected by a link N to a vertically extending rockshaft N'. Splined on this rockshaft N' is a gear wheel N2 for actuating a rack N3 on the carriage H. Thus simultaneously with the rotation of the arbors A and B a slow reciprocating movement is imparted to the arbor A in an axial direction by the movement of the carriage H. The amount of movement is determined by the adjustment of the throw of the crank M and the timing is such that for a rotational speed such as 400 R. P. M. the reciprocation of the carriage is only 4 inches per minute. The reciprocation should be proportioned to the diameter of the work to provide a selective rate of feed for each revolution of the work. The amount of reciprocation of the work is just sumcient to cause the cutting edges of the nishing tool to traverse the entire width of the work gear without permitting the work gear to pass out of contact with the guiding surfaces of the finishing tool on opposite sides of the cutting edges.

The machine is also preferably provided with automatic reversing mechanism by which, after the work has completed one stroke of the reciprocation, it is reversed and fed in the opposite dlrection. It is also preferable to reverse the direc tion of rotation of the work gear and finishing tool when the feed is reversed. Any suitable reversing mechanism may be employed but, as

diagrammatically shown in Figure 4, there is a' reversing electric switch O actuated through timing gears O which causes the reversal of the electric motor C after a predetermined number of revolutions thereof.

In the operation of the machine-as thus far K started in operation by energizing the electric motor which causes the gear and tool to roll together and at the same time to have a longitudinal feed movement of the gear in the direction of the axis thereof. At the end of the feeding stroke in one direction, the feed is automatically reversed and at the same time the direction of rotation of the cutter is preferably reversed. The head I is adjusted downwardly by means of the hand wheel 83 to cramp the gear Q against the finishing tool P. The head may be periodically adjusted downward until the desired amount of metal has been removed and the gear is entirely finished.

A modified rotary gear cutting machine is illustrated in Figures 5 to 11. In this machine a compact structure is obtained which is automatic in operation and is adaptable particularly for accurate commercial iinishlng of roughed out gears prior to heat treatment. As shown in the drawings, the frame |0| of the machine has an enlarged base portion |02 from which a column |03 extends upwardly at the rear of the machine and has a forwardly projecting portion |04. The frame of the machine is hollow and in addition to being designed to produce a rigid structure is adapted to house the driving mechanism of the machine. A head |05 adapted to swivel about a vertical axis is mounted in the forwardly projecting portion |04 of the frame. The head comprises a housing |06 having an annular bearing |01 and shoulder |08 for swivelly engaging the bearing |09 and thrust Surface ||0 of the frame portion |04. For supporting the head in position there are a plurality of supporting studs projecting through arcuate slots |||A in the frame and secured with nuts H2 in cutaway portions |06A. The nuts may be loosened during the angular adjustment of the head and tightened when the head has the desired angularity. In the upper portion of the frame is mounted an electric motor ||3 having a suitable gear reduction mechanism |4 within the hollow frame and having a driven shaft H5 depending into the head |05. A second vertical shaft H6 is journaled within the head |05 and is drivingly connected to the shaft I5 by the gears ||1 and |8. The head |05 is provided with the bearing retaining Dortions I9 and |20, the latter receiving a main bearing |2| for the horizontally arranged shaft |23. The head |05 is also provided with a cover |24 having'a second main bearing |25 for the shaft |23. For rotating the shaft, there is mounted thereon a bevel gear |26 which meshes with the bevel gear |21 on the lower end of the vertical shaft I6. The forward end of the shaft |23 is provided with'a cylindrical portion |28 on which a gear finishing tool |30 may be mounted. The tool-1? retained in position against a collar |29 by a retaining nut |3| which in turn is on a guiding spindle |32 supported within a bearing |22. With the construction thus far described, the rotation of the electric motor |3 transmitted through the gearing drives the finishing tool |30 about a horizontal axis which may be adjusted angularly if desired by means of the swivel mounting of the head |05.

Beneath the head is the work table indicated generally by the numeral 33. The table is vertically adjustable on ways |34 carried by the column |03. The table has a. bracket |35 at the rear thereof projecting into the hollow column and supporting an electric motor |36 and gear reduction mechanism |31. A coupling |38 connects the mechanism |31 to a horizontal shaft |39 which in turn is connected to the parallel shaft |40 by change gears |4| and |42. The shaft |40 is connected by bevel gears |43 and |44 to the vertical shaft |45 which in turn drives the horizontal screw |46 through the bevel gears |41 and |48. A carriage |49 is mounted on horizontal ways |50 and has a depending nut |5| engaging the screw |46 for feeding the same. will. therefore, be apparent that whenever the electric motor |36 is energized the carriage |49 will be fed axially by the feed screw |46. In order to reverse the direction of feed the electric motor |36 is reversed. For automatically reversing the carriage a suitable mechanism is provided. As shown, this comprises a lever |52 pivoted at -|53 on the table and having a lug |54 intermediate the two adjustable stops |55 on the carriage 49. The lever has a pin |56 arranged intermediate the arms |51 of a lever |58 which in turn oscillates about a shaft |59. This shaft extends within a box |60 containing a reversing electric switch which being of conventional construction is not shown in detail. It will be apparent, however. that the stops |55 on the carriage alternately oscillate the lever |52 which in turn trips the lever |58 and oscillates the shaft |59 of the reversing switch. The reversing switch is diagrammatically illustrated in the electric diagram.

The table |33 is vertically adjustable on the ways |34 by means of a hand wheel |6| in the front of the machine. This wheel is mounted on a shaft |62 extending within the hollow table and has a beveled pinion |63 thereon engaging a beveled gear |64 on a vertical shaft |65. The shaft is rotatably mounted in a bearing |66 on the table and is adapted to elevate and lower the table through the thrust bearing |61. A feed screw |68 extends downwardly from the shaft |65 and engages a nut |69 mounted on and secured to the base of the machine. Thus by rotating the hand wheel the table may be adjusted toward and away from the head |05. For automatically feeding the table |33 toward the head |05 suitable automatic mechanism is provided. A beveled gear on the shaft |39 engages the beveled gear |1| on the horizontal shaft |12 which in turn extends into a box |13 on the opposite side of the table from the box |60. The vertical shaft |45 has a worm |14 thereon meshing with a worm wheel on a horizontal shaft |16 which also projects into the box |13 above the shaft |12. The box |13 contains the automatic feed mechanism for elevating the table |33 during the reciprocation of the carriage |49. The shaft |16 is face of the disc.

ses ,om 1' of m connected by the gears |11 and |18 to a parallel shaft |19 on which is mounted a disc |80. Attached to the disc are cam arms |8| and |82 which project outwardly beyond the outer sur- A lever |83 is fulcrumed in the box |13 at the point |84 and has its free end |85 connected by a link |86 to a ratchet mechanism |81 for periodically rotating the shaft |12. On the lever |83 is a cam roller |88 arranged in the path of oscillation of the cam arms |8| and |82 so that when either of the arms strike the roller the lever |83 is moved about its pivot |84 thus actuating the link |86. The shaft |12 carries a ratchet wheel |89 having teeth |90. A ratchet pawl |9| having a nose |92 engages the teeth |90. The ratchet pawl is pivotally mounted at |93 on a carrier |94 which in turn is slidable in the guide |95 and connected by a pin |96 to the link |86. A spring |91 normally holds the pawl in engagement with the ratchet teeth. Rotatably mounted on the shaft |12 is an adjustable arm |98 having an outer cylindrical surface |99 adapted to engage the nose |92 of the ratchet pawl.

In the operation of the ratchet mechanism as described it wil-1 be apparent that the shaft |19 being directly connected to the carriage |49 oscillates in timed relation to the reciprocation of the carriage. The gear ratio is such that during the normal reciprocation of the carriage the shaft is oscillated to a sufcient degree so that the arms |8| and |82 alternately strike the cam roller |88. Each time the cam engages the roller the ratchet mechanism is actuated causing the ratchet wheel to be advanced a predetermined distance thereby rotating the shaft |12 which in turn gives a predetermined movement to the feed screw |68. The arm |98 is set so that after a predetermined movement of the ratchet wheel |89 the surface |99 of the arm engages the ratchet pawl and prevents further feed movement of the ratchet wheel even though the shaft |19 continues to oscillate. As previously stated, the ratchet mechanism is within a box |13 011 the side of the machine and is normally closed by a door 200 controlled by the door handle 20|.

The reciprocable carriage |49 carries the head and tail stocks 202 and 203 between which may be mounted the arbor for carrying the gear to be finished. Where the gear to be finished is integral with a shaft the shaft itself may be mounted between the head and tail stocks, as illustrated in the drawings. For convenience in mounting, the shaft may be inserted between centers 204 and 205, the latter being axially adjustable by a suitable hand wheel 206. Since the gear to be nished is rotated only by the intermeshing action of the finishing tool no driving mechanism is required on the carriage 49.

The electric control mechanism for the machine is mounted in a box 201 on the same side of the table as the housing for the reversing switch. ''he various elements of the control mechanism may be of standard construction and it will be sumcient to show only the electrical diagram whereby the various elements are corelated in order to cause the operation of the various parts of the machine. The electrical diagram is shown in Figure 11. 208 and 209 are push buttons for starting and stopping the machine respectively. They are located in a switch box 2|0 at the top of the machine, as shown in Figures 5 and 6. The push buttons control a magnetic switch 2|| of conventional design.

Thus when the machine is started by pressing the starter button 208 three electric motors are simultaneously operated: the head motor H3, the table motor |36 and the oil pump motor 2l2. A hand: reversing switch 2|3 is arranged to change the direction of rotation of the head motor H3 with respect to the table motor |35 in order that the desired relation between these motors may be obtained. 2M represents an automatic stop mechanism adapted to stop the operation of the machine after a predetermined interval. The reversing switch |50 previously described as being `mechanically operated at the end of each stroke is shown in the diagram as being electrically connected to reversing contactor mechanism 2I5. This mechanism electrically reverses both the head motor H3 and the table motor |36.

In the operation of the machine as previously described the desired nishing tool is mounted in the head |05 and the gear to be finished is mounted on the carriage |49 with its axis parallel to the axis of reciprocation of the carriage. The angular relation between the axis of the gear and the axis of the nishing tool is determined by the angular setting of the head |05. The table |33 is adjusted to the necessary height to obtain intermeshing engagement between the tool and gear and the arm |98 on the ratchet mechanism is adjusted to cause the desired automatic feed of the table toward the head. When the necessary adjustments have been made the machine is set in operation by pushing the starter button 208. This energizes the head motor and table motor, the head motor rotating the finishing tool and thereby driving the gear to be nished and the table motor causing a slow feed in the direction of the axis of the gear. When the table has progressed the desired distance to finish the entire width of the gear a stop |55 trips the lever |54 thereby actuating the reversing switch IB) which through the electric contactorsl 2 l5 electrically reverses both the head motor and the table motor. This causes the finishlng tool to rotate in the opposite direction while the feed is also in the opposite direction. Just prior to the actual tripping of the reversing switch the oscillating disc |80 in the box |13 has been rotated sufiiciently to contact with the cam roller |88 and actuate the ratchet mechanism |81 thereby rotating the shaft |12 and consequently the feed screw |68. Thus at about the time of reversing of the motors the table is fed a predetermined distance toward the head thereby placing the gear and finishing tool under a predetermined cramp action for the succeeding lateral feed movement. As the operation continues the table is automatically fed toward the head at the end of each stroke until the desired amount of stock has been removed from the gear. At this point the arm |98 of the ratchet mechanism engages the pawl |9| and prevents further upward movement of the table. The gear and tool continue to rotate together and the reciprocation of the carriage continues for a predetermined movement of idling strokes during which time the surfaces of the gear teeth are given a final finishing action. At this time the automatic stop mechanism 2|4 comes into play and through the magnetic switch 2H stops each of the electric motors. The gear may then be removed and replaced by another rough cut gear and the cycle of operation is again repeated.

In the operation of the gear nishing machine shown in Figure 5 with a rotary cutter of the type shown in Figures 14 and 15 the rotary cutter is mounted in the head so that the gashes in the cutter are located over the center of rotation of the cutter head and is locked in position on the arbor which is supported on both ends in bearings.

The gear to be cut is mounted between centers and locked endwise, the table is then moved to the right or left to bring the gear under the center of the cutter head and the table is raised to bring the gear in contact with the cutter while it is stationary. The height of the table is noted on the graduations of the hand wheel and the table is then lowered and the gear is moved to the right hand end of its travel remaining in mesh with the cutter teeth. The electrical stop for this extreme of travel is then set and the horizontal table then moved to the opposite end the proper amount for the width of the gear and the electrical stop on the table is then set for this limit of travel.

The gear can then be raised to the setting obtained by Contact with the cutter and when the motors are started it will revolve the gear and move the table to one side, the cut being taken preferably against the angle of the teeth on the cutter. At the end of the stroke the table will reverse and the head motor will reverse so that with opposite directions oi' movement of the table the cutter will run in opposite directions.

At each end of the table stroke the automatic mechanism raises the work gear toward the cutter a measured amount which is to be removed on the succeeding stroke of the table. This feed occurs at each end of the table movement until the desired depth of cut is obtained as determined by the set of the ratchet feed mechanism on the left hand side of the table.

Additional strokes may be taken without fur ther feeding of the gear toward the cutter and this wil1 cause the cutter to remove the former cutter marks which are of microscopic size and give the surface of the-nished gear a higher degree of finish without material change in size of the teeth. Either at the end of the cutting strokes or the end of the cutting and idling strokes the electrical unit controlling the operation of the machine will automatically stop all the motors and bring the machine to rest at the end of the table stroke. The clamps on the work arbor are then released and the gear removed from the machine.

In deciding on the direction of rotation of the cutter and the relative travel of the table beneath the cutter it is worth noting that the cutter is rotated in such a direction relative to the table travel that the gear travels against the rotation of the cutter and against the angle of the teeth on the cutter. The best cutting action can thus be obtained although some cutting action and finishing effect is obtained with other combination of rotation of the cutter and the cross sliding motion of the gear.

Rotary gear cutting tools used in the methcd c! cutting gears The preceding description has been directed mainly to machines for carrying out my method. I will now describe certain rotary cutting tools which may be used in my method of machining gears. Figure l2 shows in perspective a rotary gear cutting tool provided with a single circumferential gash between the ends o! the teeth. Figures 13 and 13a show a modied form of gear cutting tool having a plurality of cutting edges AND PLANlNG,

aarofiaa between the ends of the gear teeth. Figure 14 illustrates another modied form of rotary gear cutting tool having a greater number of cutting edges intermediate the ends of the. teeth. In each gfgthese three modifications the cutting tool is in the form of a helical gear.

The cutting tool illustrated in Figures 13 and 13a is made up of a plurality of discs S, S2, S3 and S4, each of which has similar helical teeth. In order to form the cutting edges the flank of the tooth adjacent to the leading edge of the next disc is backed o or otherwise relieved as indicated at T on one side of the helical teeth and at T2 on the opposite side. This results in the formation of a series of cutting edges T3 on each disc. The sides of the teeth in each disc are only partially relieved, leaving unrelieved portions 'l2'`1 which serve as guides for the teeth of the work engaging therewith.

The cutting tool illustrated in Figures 14 and 27 is designated by the reference character 310 and is preferably formed from a forged high speed steel blank. The teeth 31 1 which are preferably helical are formed in the blank by hobbing to a slightly greater size than is desired in the finished cutter and at the roots of the teeth the blank is provided with a series of transversely extending holes 312. the diameter of which is greater than the normal width of the bottom of the tooth slots, thus providing a 4cylindrical relief slot. The sides of the gear teeth are provided with a series of serrations 313 extending from the tops of the teeth to the clearance slots 312. These serrations are preferably closely spaced to form intermediate lands 314 of approximately the same width as the Width of the serrations. In one preferred cutting tool the width of the slots and the width of the lands are each .035 inch and the depth of the serrations is also .035. In order to strengthen the rotary cutting tool the thickness of the lands 315 (Figure 14) adjacent the end faces of the gear is greater than the intermediate lands 314, for example .070 inch.

The cutting tool as described after having been formed with the serrations and root relief as described is then heat treated to give the desired physical properties and is subsequently finished to give extreme accuracy to the gear teeth. The side faces 1G of the tool are ground to accurate parallelism while the inside diameter 311 of the central aperture and the outside diameter 318 of the gear teeth is finish ground. The side faces 319 of the gear teeth are then accurately ground to the exact profile desired, which while in general is of involute curvature is nevertheless preferably modified as hereinafter more fully set forth to give the exact curvature desired. The rotary cutting tool manufactured in accordance with the general directions given above`is one form of my invention. It will be noted that while the profile of the teeth is accurately finish ground, the serrations 313 intermediate the lands 314 are not ground, but retain the surface characteristics of the steel which has been heat treated but not subsequently finished. Similarly the cylindrical surfaces of the relief slot 312 are unground and have the same surface characteristics.

Various other rotary cutting tools may also be used in carrying out my invention, but as the cutting tool per se is not the subject matter of this application, they will not be referred to in detail, but reference may be had to my co-pending applications for patent, Serial Nos. 52,565 and 52,566, filed December 2, 1935.

The method of cutting gears The general method of cutting or shaving gears 1n accordance with my present invention is as follows. The rotary gear cutter is brought into intermeshing relationship with the roughed out work gear which is to be nished The axes of the cutter and work gear are crossed at an angle, preferably between 3 and 30. The Work gear and rotary cutting tool are rotated together in the manner of intermeshing gears, suitable means being provided for drivingv one of the members, which member in turn drives the other member by the intermeshing action of the teeth. Preferably the cutter is the driving member and the work gear is the driven member. During the rotation of the gear and c'utter, pressure is maintained between the same to hold both sides of the teeth of the cutter to contact with the teeth of the work gear. Thisaction causes both sides of the work gear teeth to be simultaneously nished. During the rotation of the gear and cutter a feed movement is imparted to one in the direction of the axis of the gear, Preferably this feed movement is in the form of a reciproeating motion of sucient amplitude to cause the cutting edges of the finishing tool to traverse the entire width of the work gear without permitting the work gear to pass out of contact with the finishing tool. At the end of the reciprocation in one direction the feed is automatically reversed and at the same time the direction of rotation of the cutter is preferably reversed. During the rotation and reciprocation the gear and cutting tool are periodically adjusted toward each other until the desired amount of metal has been removed from the surface of the work gear.

One of the characteristic features of the nishing action obtained by the use of the improved cutter is that the work gear is finished with a rotary tool and the accuracy of the work is predicated mainly upon the accuracy of the rotary tool itself as distinguished from the usual forms of gear cutting operations wherein the timing is a major feature. It should be noted that the cutting portions of the tool are always located between guiding surfaces and the nishing tool therefore acts not only as a cutter but also as a guide for insuring extreme accuracy of the cut. This action is illustrated in Figure 16 which is a diagram representing the development of the pitch plane of the gear and cutter. The gear 321 to be finished is shown above the cutter 3111, the axes being arranged at an angle between 3 and 30. The tooth 323 of the work gear is represented as intermeshing between the two adjacent cutter teeth 311. When the work gear tooth is caused to move in the direction of the arrow (see Figure 16) with respect to the cutter teeth, the cutting edges are as indicated at 324 formed by the intersection of the lands 314 with the sides of the serrations 313. While the cutting action takes place on these cutting edges it will be observed that the gear tooth 323 bears against the lands 311: on opposite sides of the gear tooth and on both sides of the cutting edges 324, thus accurately positioning the gear tooth 323 with respect to the tooth proles of the cutting teeth 311.

Figure 17 is another diagram illustrating the cutting action showing the gear tooth 323 between adjacent teeth 31| of the cutter. The center of crossed axes is located at 325 and at this point there is the greatest pressure of contact between the cutter and the gear because the surfaces of the cutter teeth and the gear tooth contact as arcs of circles and as shown, the maximum pressure is at the center of the crossed axes and there is backlash as indicated by the dimension 32S where the gear tooth 323 leaves the contact with the cutter. This contact between the cutter teeth and the gear tooth as will be noted in the diagram is on a. circular arc which develops a cutting action as shown in Figure 18 in which the center cuts 321 and 328 are deeper than the outer cuts 329, 330, 33| and 332 respectively. The reciprocating feed movement carries this area of greatest contact across the sharp edges of the cutter and spreads the finished surface across the entire gear tooth 323.

In order to explain my improved method of gear cutting, it is necessary to understand certain principles relating to the use of crossed axes for cutting purposes. As far as I am aware,

these principles were unrecognized prior to my Y invention.

In Figure 26 I have shown the crossed axes relation between the rotary cutting tool and the work gear. The teeth of the mating gears in this relation do not contact over their entire face width but contact in certain well defined paths which are different for gears of dierent characteristics. The band of contact on a spur gear when run with a mating gear of a different angle is substantially parallel to the line of rotation of the spur gear, varied only by the angular setting, as indicated at 323 in Figure 28. The band of contact on a helical gear extends at an angle to the tooth face as indicated at 334 in Figure 29. The angle of the band is a function of the helix angle of the gear. The width of the band of contact is determined by the dierence in helix angle of the mated gears, that is the angularity -of the crossed axes, being full width on spur running with spur, or helical running with helical of equal angles and opposite hand, and being narrow when 45 right hand is running with 45 right hand which gives, theoretically, a point of Contact and generates, theoretically, a line. The band of contact between zero and crossed axes is wide. The band of contact between and crossed axes is fairly wide. The band of contact above crossed axes is narrow. The center of the band of contact is the point of greatest pressure while at the outer edges of the band there is the point of minimum pressure. These bands of contact are formed both on the work gear and on the gear cutter, being characteristic of the helix angle of the work gear and the gear cutter respectively. When the cutter and gear are run together without axial feed movement and under crarnp action. that is with pressure between the same, the cutter teeth sink into the teeth of the work gear and mark the gear as indicated in Figure 18. The individual teeth on the cutter sink in to different depths, the greatest being in the middle at the center of the band on the Work gear. The cutter teeth at the outer edges of the cutter gear will not even touch the tooth face of the work gear.

'Ihe relative motion between the surfaces of the teeth of the cutter and the teeth of the work gear is, as shown in Figure 30, on a typical curved line 335 starting at the top of the tooth and having a curved contact until at the pitch line the relative motion is parallel to the pitch line. The curve then reverses along the pitch line and dips down toward the bottom of the tooth as indicated at 336. Due to the relative motion between the parts as described, the

teeth of the cutter gear at the upper part of the work tooth are cutting in one direction, say

right hand, and in the lower part of the tooth are cutting on a left hand edge, andat the pitch line the blade will first cut to the right and then cut to the left when it reverses. Due to this reverse cutting action when the crossed axes have a suiiicient angularity, the blades have a tendency to remove more material at, or near the pitch line than occurs at the top and bottom of the work teeth, creating what is called a hollow profile. This does not occur normally in hobs or shaper cutters. Rotary cutting tools such as shown in Figure 14 are normally modied in tooth contour so that the profile on the cutter is hollowed out to the amount which will compensate for the double cutting near the pitch line. The distance between the profile of the cutter teeth and a true involute curve is dependent on various conditions but at the pitch line it is normally within the range from .0003 to .0015 inch.

Due to the relatively deeper cutting at the center of the band of contact on the work gear, the cutting action during the feeding of the gear along the gear axis may be explained. This feeding spreads the cutting action over the entire face width of the work gear tooth and causes a uniform finishing action over the entire tooth. As the gear slowly moves across, a series of cutting actions take place on each cutting edge up to the center cutting edge of the tool which has the greatest depth. The lands beyond this center edge act as guides on the finished surface. The first blades which approach the surface of the gear are subjected to the most severe wear because the surface of the gear may have rough spots or carburized material of unequal hardness. Therefore -these blades may wear a considerable amount and throw the resulting load on the next blade and so on until the center blade will be doing the cutting. Even when the center blade is doing the cutting, the adjacent blades are cutting on the surface of the gear prior to its contact with the center blade and it is therefore protected from abuse. This accounts for a considerable amount of the extra life of the rotary gear cutters of this invention. Thus the center cutting blades in my rotary tool may be considered as the finishing blades while the outer blades may be considered as roughing blades.

It should be pointed out that there is a fundamental difference between the cutting of gears with a rotary gear cutting tool, and a rack cutting tool and also a. distinct dilference between operating with crossed axes instead of parallel axes. With rack cutting, the entire face width of the gear is in contact with the rack teeth in any position of the gear on the rack, and is in contact to a uniform depth of cut. Contrary to this, a gear in mesh with a rotary cutter set at crossed axes is in tight mesh only at the center where the two axes cross. Due to the elasticity of metals and the pressure applied, the contact represents a band of contact such as occurs when two cylinders are in contact with crossed axes. The point immediately over the center of crossed axes is a point of greatest depth of contact when cutting and this shades or tapers off in the width of the band of contact until the gear face entirely leaves the cutter face, and the cutter under these circumstances will make no mark beyond the band of contact. If a. gear is rolled along a rack suflicient to represent a distance greater than the circumference of the gear, the entire face of the gear is brought in contact with the rack teeth and is shaved. Even though a gear were rotated with a rotary euttern crossed axes indefinitely, it would only contact on a band on each tooth represented by the band of Contact between the crossed axes, being a very much wider band for small crossed axes and a much narrower band for obtuse crossed axes. Thus, whereas gears can be shaved without any lateral movement on a rack except to spread the wear on the rack, it is impossible to do this on rotary cutting with crossed axes. In rotary cutting an axial feed of the work is required in order to spread the contact of the tool and the Work across the entire face of the gear.

Due to the fact that the Contact between the gear and the rotary cutter on crossed axes is a concave surface, the edges of the blades on the tool in the center of the band cut deeper than edges of the blades more adjacent to the edges of the bank of contact and former edges therefore become finishing edges, and the latter edges can be considered as roughing edges. This materially increases the life of the cutter as the rough surfaces of the gear are first removed by the outer edges on the edge of the band of contact, and the surface is nally finished by contacting the center edges in the middle of the band of contact. It is Well recognized that the contact between cylinders on crossed axes has a profile which is not truly circular but is more nearly elliptical in profile. This is also true of the contact between a rotary cutter and the gear with crossed axes relation. It has been de-.

termined definitely that the cutter prole must be varied from an involute profile by a considerable extent in order to produce on thegear a true involute curve.

It was heretofore pointed out that the band of contact of a helical gear with a mating gear is at an angle to the plane of rotation. This is a characteristic feature of my improved cutting tool where the teeth are helical. Thus when the tool of Figure 14 is being used to cut a work gear with a. crossed axes relationship of 15 for example, not all of the edges of the serrations are actually being used for cutting. Figure 23 is a diagrammatic representation of a serrated tooth of the cutting tool with the serrations 3|3 and intermediate lands 3I4. The band of contact is represented by the shading. Assuming i'or example that there are twelve lands on each tooth face and that the center of the crossed axes is at the center of the tooth as shown at 345, it will be observed that the diagonal band of Contact passes across the cutting edges in the central portion of the tooth but that only certain portions of most of the cutting edges are in the band. The lands are designated as L1 to L12. Lands Ls and L1 are effective for substantially the entire distance from tip to root. La, L4, and L5 have the upper portions only within the band of contact while La, L9 and Lio have only the lower portions effective. The outside lands L1, L2, L11 and L12 are practically without cutting effect when the center of crossed axes is at the point 345. The effective portions of the cutting teeth as indicated above may be subdivided into those portions which do the preliminary roughing and those that do the final nishlng. This is diagrammatically illustrated by subdividing the band of contact into the finishing zone 346 and the outside roughing zones 341 and 348. Porstock is to use a shim beneath the same.

@Gini Ci? F1033??? stacle which prevents the normal axial feed when the crossed axes are at the center point 345. It then becomes necessary to adjust the cutter on its arbor so that the center of the crossed axes is near one edge 01' the tool as indicated at 349,

In this case the maior portion of the" Figure 24. band of contact on the tool is at one side only and the remainder of the tool-is inactive. ever by reversal of the tool, end-for end, the center of the crossed axes may be placed at the corresponding point 35i at the opposite end for continued usage.

Figure 25 illustrates a cutting tool in operative relation to the gear 352 on the cluster gear 353. The adjoining gear 354 is so located as to require shoulder cutting. The crossed axes center for this operation is preferably set about T16 to el.; of an inch from the face 355 of the cutter adjacent the gear 354.

There is a tendency for a rotary cutter when operated on shoulder cutting to give a slightly tapered tooth construction so that the chordal thickness is greater at the one end than at the other. One method of correcting this condition is to tilt the work tailstock 35B with respect to the head tailstock 33| so that the face angle of the cutter will keep the two sides without any taper. A convenient method of tilting the tail- In some cases it may be desirable to use the shim under the headstock to correct the condition. To illustrate, in the iinishing of a commercial transmission gear on an arbor having a length of nine and one-half inches between centers on the head and tailstocks, a shim ten thousandth inch thick will provide the necessary correction.

In practicing my improved method for nishing gears it is important that the correct direction of rotation for the rotary cutter be used in relation to the direction of the feed movement parallel to the axis of the gear or work. This is illustrated in Figures 19 to 22 inclusive. In Figures 19 and 20 a right-hand helical cutter 362 is shown nishing a left-hand helical gear 363. When the cutter is rotating clockwise, viewed from the left in Figure 19 as shown by the arrow 364, the direction of the feed should be to the right in Figure 19 as indicated by arrow 385. At the end of the feed movement when the direction of feed is reversed as shown in Figure 20 by the arrow 36S, the direction of rota.- tion of the cutter should also be reversed to move in a counter-clockwise direction as indicated by the arrow 361. Figures 21 and 22 show a lefthand helical cutter 368 for nishing a righthand helical gear 369. In this case, when the direction of rotation of the cutter is clockwise when viewed from the left as indicated by the arrow 310, the direction of feed is to the left as shown by arrow 311. When the feed movement is reversed as illustrated by arrow 312 in Figure 22, the direction of rotation of the cutter should also be reversed to a counter-clockwise movement as shown by the arrow 313.

In practicing my improved method for finishing gears it is usual to have the axes crossed from 5 to 20 depending upon the type of gear being finished. In the machine illustrated in How- Y Figures to 1l, provision is made to have the center of the crossed axes in perfect alignment with the dead center of the head. When it is desired to finish a helical gear with a helical cutter, the gea: and the cutter are usually of opposite hands such, for example, as a left-hand cutter for a right-hand gear and vice versa. By subtracting the helix angle of the cutter from the helix angle of the gear, the angular setting for the head my be determined.

Example for finishing helical gear:

Gear helix angle 30 R. H.

Cutter helix angle L. H.

Machine setting 15 Example for finishing spur gear:

Cutter helix angie 15" R. H.

Spur gear 0 Machine setting 15 The above is merely by Way of illustration, since my method may be successfully used with a crossed axes relationship other than that shown above. It is usual to use a right-hand cutter when finishing spur gears since it is more convenient to set up the machine, but the invention may also be practiced in other ways.

There is a denite relation between the crossed axes setting of the cutter and the work and the width of cut obtained for each revolution of the gear. This limits the amount of feed possible in the crossed travel of the gear, Whereas when finishing by a lapping tool it does not affect the operation. In normal size spur and helical gears with 15 crossed axes it is permissible to use a feed at the rate of .=.010 inch per revolution of work when a seven-inch cutter is rotating at a speed of four hundred feet per minute. It is one of the features of my invention that the 'feed in the direction of the axis of the gear is limited to correlate the cross travel of the work to the rotation thereof due to the infiuence of the crossed axes setting. Thus a cutter positioned with a large angle between the crossed axes. cuts across more surface of the work gear than the same cutter set to have a smaller angle between the crossed axes. If the cross feed is excessive, there is a tendency to cause a burnishing action Without a satisfactory cutting action. If the feed is very fine, it keeps the cutter so much in contact with the Work that again there is a tendency to get more burnishing action. One way to show the relation between the cross travel and the revolution of the work is to define the cross travel in one-thousandth of an inch feed of work in the direction of the Work axis per revolution of the work.

While I have indicated above that the cross feed rate may be 0.010 inch per revolution of work, this cross feed may be considerably increased under certain conditions, particularly when roughing cutters are used as a preliminary operation to nish shaving. Thus in some instances the feed may be increased up to about 0.060 inch per revolution of work.

According to my invention, both helical and spur gears may be finished. Since the band of contact is naturally Wider in the combination of a spur gear and a 15 helical cutter than it is between two helical members with 15 crossed axes, it is desirable when cutting spur gears to increase the angle of the crossed axes to a greater degree than when cutting'helical gears. As an example. for cutting a six-pitch spur gear,

it is more desirable to use a angle between the axes than a 10 angle.

Another feature of my method of finishing gears is the setting of the rotary cutter and the work gear in such relation as to compensate for the angle variation which occurs due to the varied relationship of the axes. ter and a gear are running at definite center distances with a certain angular relationship of the axes to provide a good iinishing action, it is permissible to maintain the same angular relationship for certain changes in dept-h'cutsuch, for example, as a plus or minus 0.010 inch change in depth. When. however, the change in depth is as much as plus or minus 0.050 inch, it is necessary to change .the angularity of the crossed axes in order to produce good results.

When cutting gears with a rotary tool of the type herein described operating with crossed axes, the actual cutting action of the cutting edges of the rotary tool is in the form of a reversing hook as illustrated in Figure 30. Thus the cutting action takes place on one side of a given tooth slot at the top of the cutter tooth and at the opposite side of the Slot at the bottom of the tooth. If the axial feed is excessive, the .cutter contacts the gear in a double curve 314 as illustrated in Figure 31.

What I claim as my invention is:

1. The method of finishing the teeth of a gear member to uniform dimensions from end to end which comprises meshing the gear member with a gashed, rotary tool member with the axes of said members crossed at an angle of less than 30, rotating one of said members directly, I ek atiyelytranslating said members in a plane parallel to `the. axes-"ofboth of saidnembers an amount sufficient to"causethe"teeth of said tool member to engage the teeth of said gear member adjacent one end thereof while maintaining the axes of said members rigidly spaced, relatively feeding said members toward each other substantially at the end of said translation to reduce the spacing of said axes, and reversing said relative translation to cause the contact between the teeth of said tool member and the teeth of said gear member to move progressively to the opposite ends of said gear teeth, while maintaining said axes rigidly at said new spac ing.

2. The method of nishing the teeth of a gear member to uniform dimensions from end to end which comprises meshing the gear member with a gashed, rotary tool member with the axes of said members crossed at an angle of less than 30. rotating one of said members directly, relatively translating said memhers in a plane parallel to the axes of both of said members an amount sumcient to cause the teeth of said tool member to engage the teeth of said gear member adjacent one end thereof while maintaining the axes of said members rigidly spaced, relatively feeding said members toward each other substantially at the end of said translation to reduce the spacing of said axes, reversing said relative translation to cause the contact between the teeth of said tool member and the teeth of said gear member to move progressively to the opposite ends of said gear teeth, while maintaining said axes rigidly at said new spacing, and thereafter relatively translating said members in said plane without further relative feed.

. 3. The method of finish cutting a gear having a shoulder adjacent thereto. comprising mating said shouldered work gear with a rotary gear When a rotary cutcutting tool having its axis crossed with respect to the axis of said Work gear, said cutter having a series. of cutting edges in the gear teeth thereof, adjusting the axes of said gear and cutter so that thecenter of crossed axes is adjacent the edge of said cutter nearest said shoulder, rotating one of said gear members thereby driving the other, feeding one of said gear members in the direction of the axis of said work gear and adjusting the axis of one of said gear members towards the other until the desired amount of finishing action is obtained.

4. The method of finish cutting a gear having a shoulder adjacent thereof, comprising mating said shouldered work gear with a rotary gear cutting tool having its axis crossed with respect to the axis of said work gear, said cutter having a series of cutting edges in the gear teeth thereof, adjusting the axes of said gear and cutter so that the center of crossed axes is adjacent the edge of said cutter nearest said shoulder, rotating one of said gear members thereby driving the other, feeding one of said gear members in the direction of the axis of said Work gear and agliustingtheaxis o fmone of said gear members toward the oth"until the desired amount of finishing action is obtained, slightly tilting the axisof one gear member relativtthemth'er during s".id"l'otation'ai andv feeding movements 5. The method of finishing the teeth of a gear member which comprises meshing the gear member at limited crossed axes with a rotary tool member having teeth conjugate tothe teeth c-f said gear member, the teeth of said tool member having cutting edges. rolling said gear and tool in mesh, relatively translating said members in a plane parallel to the axes of said members so as to cause the contact between the teeth 0f said members to shift from end to end of the teeth of said gear member, and relatively feeding said members toward each other substantially at the end of a translation.

6. The method of finishing the teeth of a gear member which comprises meshing the gear member at limited crossed axes with a rotary tool member having teeth conjugate to the teeth of said gear member. the teeth of said tool member having cutting edges, rolling said gear and tool in mesh, relatively translating said members in a plane parallel to the axes of said members so as to cause the contact between the teeth of said members to shift from end to end of the teeth of said gear member. and relatively feeding said members toward each other substantially at the end of a translation, and thereafter completing at least one additional stroke Without further relative feed.

ROBERT S. DRUMMOND. 

